Interchangeable mounting system for rooftop solar energy installations

ABSTRACT

Rooftop solar energy module mounting systems that incorporate interchangeable mounting bases with a solar energy module frame.

This application claims the benefit of U.S. Provisional Patent Application Nos. US 61/632,412 and US 61/699,546, filed on Sep. 4, 2012, and Sep. 11, 2012, respectively, the disclosures of which are incorporated herein by this reference.

BACKGROUND

Many embodiments of the invention relate to mounting structures for solar energy panels on building rooftops. Such solar panels may include photovoltaic panels, solar thermal panels among other solar capture devices.

Building owners and tenants are increasingly installing rooftop solar energy systems in order to reduce their electricity costs, sell power to the back to the grid, and improve their corporate sustainability posture. As solar energy systems become more popular, installers have developed several systems for securing a solar energy module or an array of solar energy modules to the rooftop of a building. Securing the solar energy module array to a building rooftop is necessary to prevent damage from movement caused by wind, earthquakes, building vibrations, and other external forces. Some installation methodologies include using weight to hold a solar energy array in place, adhering the solar energy array to the rooftop membrane, and securing the solar energy array using roof penetrating connections (e.g. bolts).

BRIEF SUMMARY OF INVENTION

Many embodiments of the present invention are related to solar energy modules (or module frames) and mounting bases for roof mounting of the modules that have standardized connection points such that mounting bases of different types can be interchanged, allowing the modules to be secured to the roof by any number of different securing methods. The solar energy module frame may have part of the frame extend beyond the solar energy module to act as a connection point for the mounting bases. In all cases, all modules, or module frames, will have connection points with the same location, spacing, orientation, and type of connection (means of securement) to the mounting bases. Likewise, all mounting bases, regardless of their means of immobilization on the roof (ballast, adhesive, or bolt or other rigid attachment), have connection points with the same location, spacing, orientation, and type of connection (means of securement) to the modules or module frames. All connections can be releasable. Connection points on all mounting base types can thus connect with all solar energy module connection point types. The connection points may allow for limited spatial movement in the X, Y, and Z directions between the solar energy module and mounting bases. This limited movement will allow different assemblies of mounting bases and solar energy modules to connect to neighboring mounting bases and solar energy modules on an uneven surface.

Many embodiments are related to mounting base types that can include a mounting base which uses weight (e.g. ballast) to secure the solar energy module to the rooftop, a mounting base that adheres to a rooftop membrane, and a mounting base which allows for a secure connection to a rigid rooftop structure, such as a roof penetrating pipe, bolt, air conditioning duct, parapet, or similar structure. The ballast type mounting base can include a tray in which to place ballast (e.g. concrete bricks), where simply the weight and friction between the ballast tray and rooftop secures the solar energy array. An adhered type mounting base may include material similar to that of the roofing membrane to allow the mounting base to be securely adhered to the rooftop membrane with an appropriate adhesive. A rigid attachment type mounting base may include a beam, pipe, or cross structure to allow a connection from the mounting base to a rigid structure on the roof.

Many embodiments of the invention include connection trays installed on the various types of mounting base. The connection trays have inside tray walls and outside tray walls. The inside tray walls connect to mounting bases using a weld, rivet, screw, staple, mechanical bend, or other securement method. Devices to be mounted to the connection tray, such as a solar energy module, have protrusion for resting in the connection trays. The connection trays are able to accept multiple mounted devices on either end, such that each connection tray may have four or more components secured therein. Mounting slots through inside tray wall and outside tray wall accept mechanical type fasteners to connect the device to be mounted. The mounting slots may be circular in shape, or slot-like to allow some freedom of movement. Each connection tray may have multiple mounting slots on either end in order to accept a range of mounting positions for the device to be mounted. Apertures through connection tray allow for the installation of additional items to be connected on the underside of the mounting base, such as a sacrificial wear material.

The ability to have interchangeable mounting base types with the same solar energy module frame, as well as the ability to use a combination of mounting base types for an array of many solar energy modules is a significant advantage over previous art. Benefits of this system include, but are not limited to, the ability to use multiple methods of securing the solar energy modules for a single rooftop array, simplified construction and takedown, and easier management of components for installers. Further, a single solar energy module frame can be manufactured to be used with all mounting base types, eliminating the need for a specialized mounting base for different building rooftop types. The interchangeable mounting bases allows for the same solar energy module frame to be secured to the rooftop in any preferred method by the installer. The mounting bases could be installed prior to arriving at the installation location (e.g. at the factory), or immediately by the installers on the roof. An array of solar energy modules with standard frames could employ a single mounting base type, or a combination of mounting base types to best secure the solar energy array to that particular roof. The present invention also offers benefits in manufacturing and distribution, where a single solar energy frame design is used for all mounting base types.

In many embodiments of the invention, extension brackets or mounts may be attached to a solar energy module frame and be connected in such a way to provide the same connection type, orientation, and location as the connections points to connect with all the mounting base types.

Many embodiments are related to a solar panel system comprising having first solar panel assembly with a first end and a second end secured to a first mounting base configured to mount to a mounting surface. The first mounting base may be configured to secure the first end of the first solar panel assembly and a second end of a second solar assembly that is positioned in front of the first solar panel assembly. There may also be a second mounting base configured to mount to the mounting surface where the second mounting base is configured to secure the second end of the first solar panel assembly and a first end of a third solar panel assembly that is positioned behind the first solar panel assembly and the first mounting base and second mounting base are configured to be interchangeable.

Many embodiments are related to a method for installing a solar panel system where, the steps include attaching a first solar panel assembly, the first solar panel assembly having a first end and a second end, to a first mounting base configured to mount to a mounting surface, the first mounting base configured to secure the first end of the first solar panel assembly and attaching a second end of a second solar assembly that is positioned in front of the first solar panel assembly to a second mounting base configured to mount to the mounting surface, the second mounting base configured to secure the second end of the first solar panel assembly and a first end of a third solar panel assembly that is positioned behind the first solar panel assembly, where the first mounting base and second mounting base are configured to be interchangeable.

In many embodiments the second end is positioned higher than the first end with respect to the mounting surface such that the solar panel is placed at an angle relative to a mounting surface. In various embodiments the second end is secured to the mounting base by a plurality of articulating legs.

In many embodiments the first and second mounting base each have elongated connection tabs that are each U-shaped in cross section and have an internal portion and an external portion for connecting to the first and/or second solar panel assemblies.

In many embodiments the connection tabs have slots for receiving a mechanical fasteners to mount the plurality of adjustable legs and plurality of frame members the slots are configured to allow freedom of movement about the mechanical fastener.

In many embodiments the first mounting base is a ballast type mounting base configured to accept a weighted object to secure the first mounting base to the mounting surface and the second mounting base is an adhesive type mounting base having an adhesive material affixed to its underside for adhering the second mounting base to the mounting surface.

In many embodiments the first mounting base is a ballast type mounting base configured to accept a weighted object to secure the first mounting base to the mounting surface and the second mounting base is an rigid type mounting base having an aperture for use for attaching the second mounting base to a fixed structure of the mounting surface.

In many embodiments the first mounting base is a rigid type mounting base having an aperture for use for attaching the second mounting base to a fixed structure of the mounting surface and the second mounting base is an adhesive type mounting base having an adhesive material affixed to its underside for adhering the second mounting base to the mounting surface.

In many the solar panel system can be configured so that multiple solar panels assemblies can be mounted to the solar panel system in an array. An array can be a system of solar panel assemblies in multiple columns and rows or in just one column or just one row.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a profile view of the integrated solar energy module and frame with a ballast type mounting base attached with an adhesive type mounting base and rigid attachment type mounting base in view representing one example of the present invention.

FIG. 2 is a profile view of the integrated solar energy module and frame demonstrating where a ballast type mounting base would install representing one example of the present invention.

FIGS. 3A, 3B, and 3C are profile views of the ballast type mounting base, adhered type mounting base, and rigid attachment type mounting base representing a few examples of the present invention.

FIG. 4 is a side view of an array of solar energy modules mounted using the standard connection points of the mounting bases representing one example of the present invention.

FIG. 5 is a top view of an array of solar energy modules mounted using a ballast type mounting base and an adhered type mounting base representing an example installation of the present invention.

FIG. 6 is an alternative embodiment of the present invention showing alternative connection trays.

DETAILED DESCRIPTION

FIG. 1 is a profile view of a solar energy module frame 100 housing a solar energy module 101 and connected to a ballast type mounting base 102 using standard connection tabs 103. The adhered type mounting base 200 and the rigid attachment type mounting base 300 are shown to demonstrate the standard connection tabs 103 common among all types of mounting bases within the scope of this invention. The standard connection tabs 103 on the ballast type mounting base 102, adhered type mounting base 200, and rigid attachment type mounting base 300 all have connection points with the same location, spacing, orientation, and type of connection (means of securement) to the mounting, and the connections at these points to the solar energy module frame 100 can be releasable connections. The solar energy module frame 100 is tilted at a desired angle by the pivotally attached leg 104. The pivotally attached leg 104 is connected to a second ballast type mounting base 102 in order to secure the two mounting bases 102 to opposite sides of the solar energy module.

FIG. 2 is a profile view demonstrating the installation of the ballast type mounting base 102 on both the front and back side of the integrated solar energy module and standard frame assembly. The same installation methodology is used for any mounting base type, such as the adhered type mounting base and the rigid attachment type mounting base. In FIG. 2, the ballast type mounting base 102 attaches to the solar energy module frame 100 at the standard connection tabs 103 using a pin 105, or similar fastener such as a bolt, screw, clip, rope, nylon webbing, etc. A second ballast type mounting base 102 with standard connection tabs 103 attaches to the pivotally attached leg 104 using pin 105, or similar fastener such as a bolt, screw, slip, rope, etc.

FIGS. 3A, 3B, and 3C are profile views of three types of mounting bases. FIG. 3A shows the ballast type mounting base 102 with standard connection tabs 103. FIG. 3B shows the adhered type mounting base 200 with standard connection tabs 103. The adhered type mounting base 200 has a material 201 that is compatible with the adhesive necessary for adhering the mounting base to the rooftop membrane. The adhered type mounting base 200 may be built with different types of material 201 in order to match a particular rooftop membrane's material type. The material 201 may extend beyond the width of the main body of the mounting base, or beyond the width of the standard connection tabs 103 in order to maximize surface area for better adhesion. FIG. 3C shows a rigid attachment type mounting base 300 with standard connection tabs 103. The rigid attachment mounting base 300 may be a box beam, or similar beam shape such as a pipe, “I” shape beam, “T” shape beam, “L” shape beam, etc. The key feature of the rigid attachment mounting base 300 is structural integrity such that it can withstand typical shear and lateral forces common to rooftop solar energy arrays, as well as the ability to be a universal attachment fixture for multiple types of connections. An array can be a system of solar panel assemblies in multiple columns and rows or in just one column or just one row, or any combination of these. In the FIG. 3C, the rigid attachment type mounting base 300 is an “L” shaped beam with mounting holes 301 along the top surface. The mounting holes 301 offer options as to where a secure connection to a rigid roof structure is made. In FIG. 3C, the rigid type mounting base 300 is connected to a rigid roof structure 303 using a connecting bar 302. The rigid roof structure 303 may be a roof penetrating pipe secured to the roof joists (not shown), or similar rigid structure such as a roof penetrating bolt, ventilation duct structure, roof parapet, etc.

FIG. 4 is a side view of an array of solar energy modules with solar energy module frame 100. An end of the solar energy module frame 106 connects to a standard connection tab 103 at standard connection tab end hole 107. The solar energy module frame 100 and pivotally attached leg 104 may connect to standard connection tab end holes 107 when the standard connection tab 103 and associated mounting bases are mounted to a solar energy module on both ends. In cases where only one solar energy module is connected to a mounting base (i.e. at the end of an array), the pivotally attached leg 104 may connect to the standard connection tab central hole 108. The standard connection tab central hole 108 allows for the weight of the solar energy module to be evenly distributed along the mounting base. The pin 105 connects standard connection tab 103 to pivotally attached leg 104 (shown), as well as solar energy module frame 106 to standard connection tabs 103. The standard connection tab end hole 107 and the standard connection tab central hole 108 may be slotted in order for the pin 105 to be able to move some limited distance. This feature will allow the mounting bases to articulate from the solar energy module due to an uneven surface, such as a bump in a rooftop.

FIG. 5 is a top down view of an array of solar energy modules with solar energy module frame 100 connected with ballast type mounting bases 102 and adhered type mounting bases 200. Solar energy module frames 100 connect to adhered type mounting bases 200 using pin 105.

FIG. 6 is an alternative embodiment of the present invention showing alternative connection trays 401, which act as the connection tabs of other embodiments. The connection trays 401 may be installed on the three types of mounting bases shown in FIGS. 3A, 3B, and 3C, or other types of mounting bases conceived. The connection tray 401 has inside tray wall 402 and the outside tray wall 403. In the figure shown, the inside tray walls 401 connect to the ballast mounting base 102 using a weld, rivet, screw, staple, mechanical bend, or other securement method. Devices to be mounted to this system, such as a solar energy panel, would have protrusions resting in the connection trays 401. The connection trays 401 may be able to accept multiple mounted devices on either end, such that each connection tray 401 may have four or more components secured. The mounting slots 404 through the inside tray wall 402 and outside tray wall 403 accept mechanical fasteners to connect the device to be mounted. The mounting slots 404 may be circular in shape, or slot-like to allow some freedom of movement. Each connection tray 401 may have multiple mounting slots 404 on either end in order to accept a range of mounting positions for the device to be mounted. The hole 405 through connection tray 401 allows for the installation of any device to be connected on the underside of the mounting base, such as a sacrificial wear material.

In the claims appended hereto, the term “a” or “an” is intended to mean “one or more.” While the exemplary embodiments have been described in some detail for clarity of understanding and by way of example, a number of modifications, changes, and adaptations may be implemented and/or will be obvious to those as skilled in the art. Hence, the scope of the present invention is limited solely by the claims as follows. 

What is claimed is:
 1. A solar panel system comprising: a first solar panel assembly, the first solar panel assembly having a first end and a second end; a first mounting base configured to mount to a mounting surface, the first mounting base configured to secure the first end of the first solar panel assembly and a second end of a second solar assembly that is positioned in front of the first solar panel assembly; and a second mounting base configured to mount to the mounting surface, the second mounting base configured to secure the second end of the first solar panel assembly and a first end of a third solar panel assembly that is positioned behind the first solar panel assembly; wherein the first mounting base and second mounting base are configured to be interchangeable.
 2. The solar panel system of claim 1 wherein the second end is positioned higher than the first end with respect to the mounting surface such that the solar panel is placed at an angle relative to a mounting surface.
 3. The solar panel system of claim 2 wherein the second end is secured to the mounting base by a plurality of articulating legs.
 4. The solar panel system of claim 1 wherein the first and second mounting base each further comprise elongated connection tabs that are each U-shaped in cross section and have an internal portion and an external portion for connecting to the first and/or second solar panel assemblies.
 5. The solar panel system of claim 4 wherein the connection tabs have slots for receiving mechanical fasteners to mount the first and second solar panel assemblies.
 6. The solar panel assembly of claim 5 wherein the slots are configured to allow freedom of movement about the mechanical fastener.
 7. The solar panel system of claim 1 wherein the first mounting base is a ballast type mounting base configured to accept a weighted object to secure the first mounting base to the mounting surface and the second mounting base is an adhesive type mounting base having an adhesive material affixed to its underside for adhering the second mounting base to the mounting surface.
 8. The solar panel system of claim 1 wherein the first mounting base is a ballast type mounting base configured to accept a weighted object to secure the first mounting base to the mounting surface and the second mounting base is an rigid type mounting base having an aperture for use for attaching the second mounting base to a fixed structure of the mounting surface.
 9. The solar panel assembly of claim 1 wherein the first mounting base is a rigid type mounting base having an aperture for use for attaching the second mounting base to a fixed structure of the mounting surface and the second mounting base is an adhesive type mounting base having an adhesive material affixed to its underside for adhering the second mounting base to the mounting surface.
 10. The solar panel system of claim 1 configured such that multiple solar panels assemblies can be mounted to the solar panel system in an array.
 11. A method for installing a solar panel system, the steps comprising: attaching a first solar panel assembly, the first solar panel assembly having a first end and a second end, to a first mounting base configured to mount to a mounting surface, the first mounting base configured to secure the first end of the first solar panel assembly; and, attaching a second end of a second solar assembly that is positioned in front of the first solar panel assembly to a second mounting base configured to mount to the mounting surface, the second mounting base configured to secure the second end of the first solar panel assembly and a first end of a third solar panel assembly that is positioned behind the first solar panel assembly; wherein the first mounting base and second mounting base are configured to be interchangeable.
 12. The method for installing a solar panel system of claim 11 wherein the second end is positioned higher than the first end with respect to the mounting surface such that the solar panel is placed at an angle relative to a mounting surface.
 13. The method for installing a solar panel system of claim 12 wherein the second end is secured to the mounting base by a plurality of articulating legs.
 14. The method for installing a solar panel system of claim 11 wherein the first and second mounting base each further comprise elongated connection tabs that are U-shaped in cross section and have an internal portion wherein the first and second solar panel assemblies attach to the inside of the respective connection tabs.
 15. The method for installing a solar panel system of claim 14 wherein the connection tabs have slots for receiving mechanical fasteners to mount the plurality of adjustable legs and plurality of frame members.
 16. The solar panel system of claim 15 wherein the slots are configured to allow freedom of movement about the mechanical fastener.
 17. The method for installing a solar panel assembly claim 11 wherein the first mounting base is a ballast type mounting base configured to accept a weighted object to secure the first mounting base to the mounting surface and the second mounting base is an adhesive type mounting base having an adhesive material affixed to its underside for adhering the second mounting base to the mounting surface.
 18. The method for installing a solar panel system claim 11 wherein the first mounting base is a ballast type mounting base configured to accept a weighted object to secure the first mounting base to the mounting surface and the second mounting base is an rigid type mounting base having an aperture for use for attaching the second mounting base to a fixed structure of the mounting surface.
 19. The method for installing a solar panel system claim 11 wherein the first mounting base is an rigid type mounting base having an aperture for use for attaching the second mounting base to a fixed structure of the mounting surface and the second mounting base is an adhesive type mounting base having an adhesive material affixed to its underside for adhering the second mounting base to the mounting surface
 20. The solar panel system of claim 11 configured such that an array of solar panels assemblies can be mounted to the solar panel system. 